Machine for making frame blanks and for thereafter forming said blanks around an article



Aug. 27, 1968 H. N WATROUS 3,398,660

MACHINE FOR MAKING FRAME BLANKS AND FOR THEREAFTER FORMING sun BLANKSAROUND AN ARTICLE Filed Sept. 20, 1966 8 Sheets-Sheet l IIIII rlllllIIIEF Fig. 2

an N INVENTOR. Howard Nv Wofrous ATTORNEY Aug. 27, 1968 WATROUS3,398,660

MACHINE? FOR MAKING FRAME BLANKS AND FOR THEREAFIER FORMING SAID BLANKSAROUND AN ARTICLE Hled Sept. 20. 1966 8 Sheets-Sheet 2 F 9 INVENTOR.Howard N. Wctrous ATTORNE Y Aug. 27, 1968 N WATROUS 3,398,660

MACHINE; FOR MAKING FRAME BLANKS AND FOR THEREAFTER FORMING SAID BLANKSAROUND AN ARTIQLE E lied Sept. 20, 1966 8 Sheets-Sheet 5 INVENTOR.Howard N. Wotrous ATTORNEY Aug. 27, 1968 H WATRQUS 3,398,660

MACHINE FOR MAKING FRAME BLANKS AND FOR THEREAFTER FORMING SAID BLANKSAROUND AN ARTICLE Filed Sept. 20, 1966 8 Sheets-Sheet 4 IIIIIII/IlINVENTOR. Howard N. Wotrous BYW ATTORNEY Aug. 27, 1968 N WATRQUS3,398,660

MACHINE FOR MAKING FRAME ELANKS AND FOR THEREAFTER FORMING SAID BLANKSAROUND AN ARTICLE Filed Sept. 20, 1966 8 Sheets-Sheet Fig.

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MACHINE FOR MAKING FRAME BLANKS AND FOR THEREAFTER FORMING SAID BLANKSAROUND AN ARTICLE Filed Sept. 20, 1966 8 Sheets-Sheet 6 INVENTOR. HowardN. Wotrous ,4 w

ATTORNEY Aug. 27, 1968 H. N WATROUS MACHINE FOR MAKING FRAME BLANKS ANDFOR THEREAF'IER FORMING SAID BLANKS AROUND AN ARTICLE 8 SheetsSheet 7Filed Sept. 20, 1966 Illllalll mvm mmm

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Aug. 27, 1968 H N. WATROUS MACHINE FOR MAKING FRAME BLANKS AND FORTHEREAFTER FORMING SAID BLANKS AROUND AN ARTICLE Filed Sept. 20, 1966Sheets-Sheet B Howard N. Wmrous A T TORNE Y United States Patent3,398,660 MACHINE FOR MAKING FRAME BLANKS AND FOR THEREAFIER FORMINGSAID BLANKS AROUND AN ARTICLE Howard N. Watrous, Cincinnati, Ohio,assignor to The Procter & Gamble Company, Cincinnati, Ohio, acorporation of Ohio Filed Sept. 20, 1966, Ser. No. 580,774 26 Claims.(CI. 93-49) This invention relates to the art of packaging machines.More particularly, the invention relates to a machine for transforming acut and scored flat blank of packaging material into a frame blank andthereafter forming and folding same around an article to provide asupporting frame for the article.

The inventive concept involves the provision of a machine which has asits primary object the capability of making frame blanks of the typegenerally disclosed in FIGURE 2 of US. Patent 3,159,274 issued on Dec.1, 1964, to Robert V. Burt and commonly owned by the .assignee of thepresent invention. In a generic sense, the machine has the ability toform the tubular support elements of the frame blank in any desiredcross-sectional shape or configuration, e.g., triangular, rectangular,arcuate or the like. In the preferred form of the machine as hereindescribed, the tubular support elements of the frame blank are formedinto an arcuate configuration.

In addition to the above, the machine of the invention has thecapability of folding and forming each successive frame blank into asupporting frame around an article of the type as also disclosed in theaforesaid Burt patent. When the article is assembled within and held bythe supporting frame, the combination forms a unitary rigid packagestructure which can be overwrapped, if desired, by any equipment capableof doing so such as, for example, the machine illustrated and describedin US Patent 3,149,446 issued on December 21, 1964, to Charles R. Hoodand commonly owned by the assignee of the present invention.

Brief summary of the invention The machine of the present inventioncomprises a succession of operating sections which act sequentially on afiat packaging blank to transform it initially into a frame blank havingtubular support elements along its edges. The frame blank is thereafterfolded and formed around an article to enclose and support the articleand thus provide a suitable supporting frame.

A stack of flat packaging blanks are initially placed in the machine.Each of the packaging blanks are cut and prescored into a plurality ofadjoining wall panels having extending portions projecting laterallyfrom the side edges thereof. The stack of fiat packaging blanks areplaced in a hopper from which they are successively fed in single fileorder to pass through the machine. Successive fiat blanks are removedfrom the bottom of the hopper by a suitable blank feeding device whichpasses each individual blank to a pair of forwarding rolls from whichthe blanks are fed to an alignment section.

In the alignment section the successive fiat packaging blanks are movedforward and slightly laterally while in contact with a stationary guide.On leaving the alignment section the side edges of the flat blanks arein proper later alignment for feeding to the tubular support formingsection.

In the tubular support forming section the extending side portions ofthe flat blank are folded and manipulated at relatively high speed andwithout any stretching of the blank to form the tubular support elementsof the frame.

A plurality of appropriately shaped folding and bending rolls areprovided for this purpose which act on the blank in sequence as it movesthrough the machine.

On completion of folding, bending and forming the tubular supportelements for the frame blank, a narrow bead of adhesive is applied onthe wall panels of the frame blank beneath the tubular support elements.The tubular support elements are then presseed down into place. Theframe blanks next pass through a compression section which holds theframe blanks in their desired assembled configuration while the adhesivesolidifies.

Successive frame blanks may then be delivered from the compressionsection to a surge section on the machine in which a plurality ofcompleted frame blanks can be accumulated. The frame blanks arethereafter fed from the surge section to a cross direction foldingsection by means of an escapement linkage. Each frame blank is thenformed into a rectangular supporting frame by suitable folding elementsand placed around an article being packaged. The supporting frame iscompleted around the article by additional folding and tucking means asthe frame and article are moved forward in unison. The assembled framemay be overwrapped if necessary or desirable although the detail of themechanism for overwrapping does not form a part of the presentinvention.

Brief description of the several views of the drawings FIGURE 1 is afragmentary plan view of the machine, portions of which have beenremoved for clarity of illustration.

FIGURE 2 is a fragmentary elevation view of the machine of FIGURE 1taken on the line 22 of FIGURE l.

FIGURE 3 is a fragmentary end elevation view of the machine taken on theline 33 of FIGURE 1.

FIGURE 4 is a fragmentary plan view of the product conveyor taken on theline 4-4 of FIGURE 3.

FIGURE 5 is a fragmentary detailed plan view of the hopper of themachine illustrated with a stack of packaging blanks in place.

FIGURE 6 is a fragmentary elevation view of the hopper in cross sectiontaken on the line 6-6 of FIG- URE 5.

FIGURE 7 is a fragmentary plan view illustrating the first pair offolding rolls acting on a packaging blank.

FIGURE 8 is a fragmentary elevation view of the folding rolls in crosssection taken on the line 8-8 of FIGURE 7.

FIGURE 9 is a fragmentary plan view showing several sets of bendingrolls acting successively on a packaging blank.

FIGURE 10 is a fragmentary elevation view of the first set of bendingrolls in cross section taken on the line 10-10 of FIGURE 9.

FIGURE 11 is a fragmentary elevation view of the second set of bendingrolls in cross section taken on the line 11-11 of FIGURE 9.

FIGURE 12 is a fragmentary elevation view of the third set of bendingrolls in cross section taken on the line 12-12 of FIGURE 9.

FIGURE 13 is a fragmentary plan view of additional folding, bending, andforming means acting successively on a packaging blank.

FIGURE 14 is a fragmentary elevation view of the folding element incross section taken on line 14-14 of FIGURE 13.

FIGURE 15 is a fragmentary elevation view of the folding element incross section taken on the line l5l5 of FIGURE 13.

FIGURE 16 is an additional fragmentary elevation view of the foldingelement in cross section taken on the line 16-16 of FIGURE 13.

FIGURE 17 is a fragmentary elevation view of a pair of folding rolls incross section taken on the line 17-17 of FIGURE 13.

FIGURE 18 is a fragmentary elevation view of a pair of forming rolls incross section taken on the line 18-18 of FIGURE 13,.

FIGURE 19 is a fragmentary plan view taken at the end of the tubularsupport forming section showing folding and forming members, theadhesive applicator, and the beginning of the compression section.

FIGURE 20 is a fragmentary elevation view taken at the inlet of thefolding member in cross section on the line 20-20 of FIGURE 19.

FIGURE 21 is a fragmentary elevation view through the folding member incross section taken on the line 21-21 of FIGURE 19.

FIGURE 22 is a fragmentary elevation view through the folding member incross section taken on the line 22-22 of FIGURE 19.

FIGURE 23 is a fragmentary elevation view at the inlet to the adhesiveapplicator in cross section taken on the line 23-23 of FIGURE 19.

FIGURE 24 is a fragmentary elevation view at the adhesive applicator incross section on the line 24-24 of FIGURE 19.

FIGURE 25 is a fragmentary elevation view of the final folder in crosssection on the line 25-25 of FIGURE 19.

FIGURE 26 is a fragmentary elevation view of the final folder in crosssection on the line 26-26 of FIGURE 19.

FIGURE 27 is a fragmentary elevation view of the final folder in crosssection taken on the line 27-27 of FIGURE 19.

FIGURE 28 is a fragmentary elevation view in cross section on the line28-28 of FIGURE 19 and illustrating the inlet to the compressionsection.

FIGURE 29 is a fragmentary side elevation view showing the escapementlinkage in cross section taken on the line 29-29 of FIGURE 1.

FIGURE 30 is a fragmentary plan view at the end of the surge section incross section taken on the line 30- 30 of FIGURE 29.

FIGURE 31 is a fragmentary plan view in cross section taken through thecross direction folder at the line 31-31 of FIGURE 3.

FIGURE 32 is a fragmentary plan view in cross section taken through thecross direction folder at the line 32-32 of FIGURE 3.

FIGURE 33 is a fragmentary perspective view taken at the end of theproduct conveyor showing the mechanism for completing the supportingframe around the article.

FIGURES 34, 35, and 36 are fragmentary perspective views similar toFIGURE 33 showing the sequence of operations formed on the frame blankto complete the supporting frame.

FIGURE 37 is a fragmentary plan view showing the drive mechanism for thevarious elements of the machine.

FIGURE 38 is a fragmentary elevation vew of the machine drive taken onthe line 38-38 of FIGURE 37. This view is taken from the opposite sideof the machine as shown in FIGURE 2.

FIGURE 39 is a fragmentary elevation view of the drive for theescapement linkage and the conveyor in the surge section.

FIGURE 40 is a fragmentary plan view of an alternate set of bendingrolls which can be employed in the machine of this invention.

FIGURE 41 is a fragmentary elevation view of one set of bending rolls incross section taken on the line 41-41 of FIGURE 40.

FIGURE 42 is a plan view of the fiat packaging blank which is placed inthe machine.

FIGURE 43 is a plan view of a frame blank which is 4 made by the machinefrom the packaging blank of FIGURE 42.

FIGURE 44 is a perspective view of a finished and assembled supportingframe made by the machine from the frame blank of FIGURE 43.

FIGURE 45 is a fragmentary elevation view in cross section taken throughthe package on the line 4343 of FIGURE 42.

Package made by machine As previously indicated, the present machine wasinvented for making a supporting frame for a package of the typegenerally disclosed in US. Patent 3,159,274 issued to Robert V. Burt.The machine is particularly suited to making a preferred form of thepackage of the type described in the Burt patent for a bar of soap orthe like. In its finished form the preferred package frame is shown inFIGURES 44 and 45 of the drawings.

The package frame is made from a fiat packaging blank 51 of the kindshown in FIGURE 42. The blank 51 is preferably made from a typicalpackaging material such as paperboard, cardboard, or the like. The blank51 in FIGURE 42 is cut and prescored prior to being stacked in themachine hopper such that longitudinal score lines 52 and 53 are providedrunning the length of the blank and a series of vertical scores 54, 55,56, and 57 are provided to divide the blank into a series ofside-by-side wall panels 58, 59, 60, and 61 and an end tab 62. Extendingportions 63, 64, 65, and 66 on the upper side and 63a, 64a, 65a and 660on the lower side are separated by angular relief cut-outs 67, 68, and69 on the upper side and 67a and 68a, and 69a on the lower side. Theextending portions 63 66 are divided by a score line 70 into an innerarea 71 and an outer area 72. The blank is symmetrical such that theextending portions 63a 66a on the lower side as viewed in FIGURE 42 aresimilarly scored on the line 70a to form the inner areas 73 and theouter areas 74. The blank 51 is referred to throughout thisspecification as a packaging blank.

The packaging blank 51 is initially folded and formed into a frame blank75 as shown in FIGURE 43. In the frame blank 75 the extending portions63, 64, 65, and 66 have been suitably bent, and folded to transform thefiat inner area 71 into a tubular support 76. Similarly, the inner area73 has been transformed into the tubular support 77. The outer areas 72and 74 are adhered to the respective wall panels 58, 59, 60, and 61 asshown, for example, in cross section in FIGURE 45. It will also beapparent from FIGURE 45 that the preferred frame blank formed by thepresent machine has tubular support elements 76 and 77 of arcuateconfiguration although other shapes can be formed, if desired. The frameblank as fabricated to the point illustrated in FIGURE 43 will bereferred to throughout this description as a frame blank 75 todistinguish it from the packaging blank 51.

The completed frame blank 75 is folded along its vertical scores 54, 55,56, and 57 to form it around an article so that the tubular supports 76and 77 engage its surfaces. In FIGURE 44, for example, a bar of soap 78is snugly held on four sides by the tubular supports 76 and 77. FIGURE44 illustrates the complete supporting frame 79 in which the end tab 62has been tucked in place inside the wall panel 61. The complete frame asseen in FIGURE 44 will be referred to throughout the description as asupporting frame 79 in order to distinguish it from the frame blank 75and the packaging blank 51.

The supporting frame 79 may, if desired, be overwrapped with an opaqueor transparent wrapper by the use of conventional apparatus, the scopeof which is beyond the contemplation of the present invention.Overwrapping can be carried out in an apparatus of the type described inthe aforesaid Hood Patent 3,149,446. However, the supporting frame 79can also be considered a finished package even though it might befurther processed in a preferred form.

General machine arrangement Before describing the detailed constructionof the machine, it is believed that a general discussion of itsconstruction would be desirable at this point so that the more detailedstructure will be more easily understood. The machine can be dividedinto a number of operating sections which act successively on flatpackaging blanks 51 continuously and at relatively high speeds in orderto ultimately arrive at a supporting frame enclosing a bar of soap 78 orany equivalent article. Speeds in excess of 300 completed supportingframes per minute can be achieved with the present machine structure.

Referring now to FIGURES 1 through 4, the hopper section 80 is locatedat the inlet to the machine. A vertical stack of fiat packaging blanks51 are placed in the hopper section. Successive fiat packaging blanks 51are withdrawn from the bottom of the stack from where they are fed tothe alignment section 81 in which the blanks 51 are laterally alignedwith respect to their side edges prior to the folding, bending, forming,and gluing operations.

A tubular support forming section 82 is provided for folding, bending,and forming the fiat packaging blanks 51 to produce the tubular supports76 and 77. Adhesive applicator means are provided for adhering the outerareas 72 and 74 to the inner surfaces of the wall panels 58, 59, 60, and61. The compression section 83 is provided to hold the frame blank 75 inproper configuration as it moves forward until the adhesive has set.

A surge section 84 is provided in which a plurality of frame blanks 75can be collected and fed laterally until ready for the next formingoperation. The length of the surge section is such that it can be usedas a storage reservoir, if necessary, to collect all frame blanks inprocess from the hopper section 80 and beyond such that partiallyfabricated frame blanks will not be left in the machine in the event ofan unexpected shutdown. The surge section 84 also acts as a supplysource for frame blanks 75 when starting up the machine until additionalframe blanks 75 are received from the compression section 83.

A cross direction folding section 85 is provided to which the frameblanks 75 are fed from the surge section 84. In the cross directionfolding section 85 the frame blanks 75 are folded on their verticalscores 54, 55, 56, and 57 to transform them into substantiallyrectangular form prior to delivery over and around a bar of soap 78.

The partially erected frame blanks 75 are placed over and aroundsuccessive bars of soap 78 on the product conveyor 86 as seen in FIGURE4. Thereupon they are moved forward and then clamped between themandrels 87 and 88 to be moved through the last sequencse of folding andtucking wherein the tab 62 is pushed into place to complete thesupporting frame 79 around the bar of soap 78.

Hopper section The hopper section 80 generally illustrated in FIG- URES1 and 2 is shown in greater detail in FIGURES 5 and 6. The hopper 89 iscomposed of a plurality of side Walls 90, 91, 92, and 93 positioned toreceive a stack of flat packaging blangs 51. The packaging blanks 51 aresupported on one side by the blank supports 94, 95, and 96 which projectinwardly from the wall 90. A similar set of supports 97, 98, and 99 areprovided projecting inwardly from the side wall 92. Alignment guides 100and 101 project upwardly in the angular relief areas 69 and 69a of theblanks to maintain them in proper alignment in the hopper. It will beseen that by supporting the trailing edge of the extending portions 63,63a, 64, 64a, 65, and 65a of the fiat packaging blanks, the blanksupports 94 98 prevent gating and permit removal of successiveindividual blanks 51 from the stack for feeding to the driven forwardingrolls 102 and 103.

Successive packaging blanks 51 are removed from the bottom of the stackby the vacuum cup device and its associated linkage now to be described.As seen in FIG- URE 6, a plurality of vacuum cups 104 are secured to avacuum manifold 105 which is hollowed and communicates with a vacuumsource (not shown) by means of the flexible conduit 106.

The mechanism for moving the vacuum cups includes a crank 107 which isrotated continuously by the shaft 221 (see FIGURES 5, 37, 38) and drivesa connecting member 108 which is pivoted at 109 to the crank 110 whichis journaled on the member 111. The vacuum manifold 105 is pivoted at112 to the connecting member 108. The forward end of the vacuum manfold105 is pivoted at 113 to a connecting rod 114 the lower end of which ismoved in a circular path by the crank 115 turned continuously by theshaft 223 (FIGURES 37 and 38).

Thus, on rotation of the cranks 107 and 115, the vacuum cups 104 areengaged against the bottomost member of the stack of blanks 51. Vacuumis applied and the manifold 105 is moved forwardly and slightlydownwardly. The cups 104 pick up and carry the bottom blank 51 to removeit from the stack. This bottom blank is delivered to the nip of theforwarding rolls 102 and 103 (FIGURES l, 2, 5, and 6) which arepositively driven to continue the forward movement of the blank. Whenthe leading edge of the blank is engaged by the forwarding rolls 102 and103, vacuum is removed from the vacuum cups 104 so that they disengagethe blank whereupon they are returned for the next cycle by themechanism previously described. The mechanism for moving the vacuum cups104 is a modified four-bar linkage.

The machine may be operated at times when blank feeding is not desiredfor brief intervals. During these periods, vacuum is not applied to thevacuum manifold 105 and yet the vacuum cups 104 will engage and tend todislodge the bottom blank 51 in the hopper 89. To prevent thisphenomenon during such periods, the cross support member 290 is providedwith a slot 291 and apertures 292 leading to a conduit 293 which is alsoconnected to a vacuum source (not shown). The control for the blank feedsystem (to be hereinafter explained) is operated so that vacuum isapplied to the slot 291 during such periods when no blank feedingoccurs. The vacuum in the slot 291 prevents the bottom blank 51 frombeing carried forwardly by frictional engagement with the vacuum cups104.

The control mechanism for applying and exhausting vacuum includes afour-way valve (not shown) the inlet of which communicates with a vacuumpump (not shown). The four-way valve is controlled by a portion of theelectrical control circuit of the machine. The fourway valve controlsthe vacuum to the slot 291 by means of the conduit 293. The four-wayvalve also controls the vacuum to the cups 104 through an intermediatethreeway valve (not shown). A switch 117 is provided with a follower 118which rides on the surface of the cam 116 rotating continuously on theshaft 221. The switch 117 actuates the three-way valve to periodicallyapply and release vacuum to the conduit 106 unless overridden by thefour-way valve. The operative details of this arrangement are believedto be conventional and will be familiar to persons skilled in the art.

A lignment section The alignment section 81 is best seen in FIGURES 1and 2. It consists of an endless belt 119 driven continuously andmounted over the support pulleys 120 and 121. A pair of alignmentrollers 122 supported on the arms 123 bear down against the belt 119 andkeep successive packaging blanks 51 in firm engagement with the belt.Springs 124 are provided to bias the rollers 122 against the belt.

The rollers 122 are slightly angled to that they move the packagingblanks 51 slightly laterally against the edge 125a of the guide 125running the length of the alignment section 81. As a result, eachpackaging blank becomes properly aligned as it is fed into the secondset of driven forwarding rollers 126 and 127. It will be noted in FIGURE1 that the edge 125a of the guide 125 is at a slight angle with respectto the line of movement of the belt 119 in order to gradually bring eachof the packaging blanks into alignment as it is carried forward.

Tubuiar support forming section After passing through the alignmentsection, the packaging blank 51 is in proper lateral position forfolding, bending, and forming the tubular support elements 76 and 77. Asa first step the packaging blank 51 is passed between a first pair offolding rolls consisting of an upper roll 128 and a flanged lower roll129 (see FIGURES 1, 2. 7, and 8). In passing between the rolls 128 and129, the blank 51 is folded on the score lines 70 and 70:: whichseparate the outer areas 72 and 74 from the inner areas 71 and 73,respectively.

From the first set of folding rolls the blanks 51 are then passedthrough a series of bending rolls for contouring the arcuate portion ofthe tubular support elements 76 and 77. This is done by bending thepackaging blank 51 in the inner areas 71 and 73 at spaced intervalsbetween the score lines which define the inner areas 71 and 73. Bendingis accomplished without stretching of the board material by means of therolls shown generally in FIGURES 1 and 2 and in greater detail in FIGURE9.

The bending rolls are arranged in sets such that succesive upper rolls130, 131, and 132 are of diminishing width. As seen in FIGURE 10, thefirst upper roll 130 cooperates with a pair of tapered rolls 133 and 134which combine to form the first set of bending rolls in forming thepackage blank. The tapered rolls 133 and 134 are urged upwardly againstthe roll 130 by means of the springs 135 which bear against the frame136 at one end and against the collars 137 at the other end. Thus, asthe rolls 130, 131, and 132 are driven (by means to be describedhereinafter) the tapered rolls 133 and 134 tend to be frictionallydriven due to the pressure of the springs 135 urging the rolls 133 and134 upwardly against the blank interposed against the roll 130.

A similar arrangement is provided for the second set of bending rollscomprising the upper roll 131 and the tapered rolls 138 and 139 (seeFIGURE 11). The tapered rolls 138 and 139 are mounted in similar fashionto the rolls 133 and 134. The last set of bending rolls is shown inFIGURE 12. This set consists of the upper roll 132 which coacts with theangular rolls 140 and 141 the latter again being supported and springurged as in the case of the tapered rolls 133 and 134. On passingthrough the last set of bending rolls, the packaging material of theblank 51 is sutficiently flexed and bent in the inner areas 71 and 73 tobe readily formed into a tubular support 76 and 77 of substantiallyarcuate cross section.

The blank is thereafter carried through the additional folding andforming elements illustrated in FIGURES l, 2, and 13. The blankinitially is passed through a folding element 142 and under a guideelement 143 which combine to fold over the outer areas 72 and 74 flatagainst the blank in order to form a reasonably sharp crease. Crosssections through the folding element 142 are seen in FIGURES 14, 15, and16 where it can be seen how the movement of the blank results in thefolding action heretofore described. It will be noted that the guideelement 143 maintains the blank against the table or plate 144 such thatthe downward curvature of the folding element 142 will cause the blankto leave in the configuration shown in FIGURE 16.

The blank is then carried to the second set of folding rolls as shown inFIGURES l, 2, l3, and 17. These folding rolls consist of an upper roll145 and a flanged lower roll 146 suitably driven at substantiallyconstant speed by means to be described hereinafter. The rolls 145 and146 form a reasonably sharp crease in the blank 51 along the horizontalscores 52 and 53.

Blanks 51 are then fed to the forming rolls shown in FIGURE 18 whichconsist of an upper roll 147 having V-notches 148 and 149 on oppositesides and a sheave 150 having an endless belt 151 running thereover. Thenotches 148 and 149 open and shape the tubular elements 76 and 77 fromthe flat position assumed when passing between the folding rolls 145 and146. As a consequence, the tubular support elements 76 and 77 are formedprior to passage of the blank 51 into the last phase of the folding,bending, and forming device shown in FIG- URES I, 2, and 19.

The blanks 51 are now carried forward by the belt 151 into a foldingmember 152 which is hollowed and properly shaped to cause furtherbending on the horizontal scores 52 and 53 which will be observed froman examination of the successive cross sections taken through thefolding member 152 as exemplified by FIGURES 20, 21, and 22.

On leaving the folding member 152, the blank passes beneath the idlerroller 153 and then to the adhesive applicator device. The belt 151passes downwardly over the pulley 1.54 and around the pulley 155 asillustrated in FIGURE 23. This provides clearance beneath the ad hesiveapplicator. The belt passes upwardly and around the pulley 156 to returnto ts path of travel as best seen in FIGURES 2 and 24.

The blank 51 then passes under the adhesive nozzle 157 which ispreferably supplied with any well known hot melt adhesive which can beapplied through the apertures 158 and 159. As a result, two thincontinuous stripes of adhesive 160 and 161 are applied to the wallpanels 58, 59, 60, and 61 of the blank 51 beneath the outer areas 72 and74. The blank then passes through a final folder element 162 whereuponthe tubular supports 76 and 77 are progressively moved downwardly asshown in sequence by FIGURES 25, 26, and 27 such that the outer areas 72and 74 are pushed against the adhesive stripes 160 and 161 to completethe formation of the frame blank 75.

Compression section On leaving the final folder 162, the frame blank 75moves into the compression section 83, the inlet of which is shown inFIGURE 28. In the compression section, the belt 151 carries the frameblank 75 beneath the elongated endless belt 163 which has a series ofspaced rollers 164 (see also FIGURE 2) which hold it in engagement atthe convergence of the tubular support element 76 and 77. As aconsequence the adhesive stripes 160 and 161 tend to set as the frameblank 75 moves through the compression section 83. On being dischargedfrom the compression section 83 the adhesive has set sufiiciently sothat the frame blank 75 is complete when it is discharged into the surgesection 84.

Surge section The frame blanks 75 are delivered to the surge section asshown in FIGURES l, 2, and 3 beneath the rotating bristled element 165.The speed of the machine is such that the completed frame blanks 75 aredelivered at such a velocity as to cause a tendency to bounce off theguide wall 166 on delivery to the surge section. However, the rotationof the bristled element while in contact with the upper surface of aframe blank prevents such bounce and permits the frame blanks 75 to becarried laterally by means of the pusher elements 172 on the lateralchain conveyors 173 and 174. The frame blanks 75 are then delivered tothe conveyor belts 167 and 168 for movement to the end of the surgesection. The guides 169 and 170 (FIGURES 2, 29, and 30) maintain theframe blanks 75 in engagement with the belts 167 and 168 as they moveforward and until they are restrained from further movement by thespring elements 171 (FIG- URE 29) which hold back the frame blanks andallow slippage of the belts 167 and 168 on their lower surface.

The length of the surge section is such that a substantial number offrame blanks 75 can be accumulated in the event the next segment of themachine has no demand for frame elements. This permits all partiallyformed frame elements in the hopper section 80 and beyond to becompleted and fed into the surge section when no additional frame blanksare being fed. In other Words, the hopper section 80, the alignmentsection 81, the tubular support forming section 82, and the compressionsection 83 can be cleared of partially formed frame blanks and whencompleted, these can be stored in the surge section until picked out andfed by the escapernent linkage to be hereinafter described. Accumulatedframe blanks 75 in the surge section 84 also act as a supply source whenstarting up the machine until additional new frame blanks 75 arereceived from the compression section 83.

Escapement linkage An escapernent linkage is provided to remove and feedsuccessive frame blanks 75 from the surge section 85 by overcoming thetension in the spring elements 171. The escapernent linkage is best seenin FIGURES 3 and 29.

A drive shaft 175 is suitably journaled in the support plate 176. Adriving crank 177 is keyed to the shaft 175. A picker finger 178 ispivoted to the driving crank 177 at the pin 179.

A connecting member 180 is pivoted at 181 to the picker finger 178. Theupper end of the connecting member 180 is journaled on the pin 182 whichis secured to the arm 183. The arm 183 is keyed to the shaft 184 whichis journaled in the support plate 176.

The connecting link 185 is also keyed to the shaft 184. The upper end ofthe connecting link 185 is attached to the armature 186 of the solenoid187. A spring 188 is provided such that one end is attached to the lowerend of the connecting link 185 and the other end is attached to themachine frame.

In the position shown in FIGURE 29, the solenoid 187 is deenergized suchthat the spring 188 pulls the solenoid armature 186 to its deenergizedposition thereby causing the arm 183 to rotate clockwise and therebylowering the pivot 181 so that the sharp end 189 of the picker finger178 engages and picks off a frame blank 75 on each revolution of thedriving crank 177. The path of movement of the sharp end 189 is denotedby the dot-dash line 212.

When the solenoid 187 is energized, the arm 183 is rotatedcounterclockwise by the shaft 184. This raises the pivot 181 such thatthe sharp end 189 will clear the frame blanks 75 being held by thespring elements 171. In the latter position, the path of movement 212will be similar but raised sufficiently so that the end 189 will clearthe frame blanks 75.

The illusrtated mechanism is duplicated on the far side of the solenoid187 so that a pair of spaced picker fingers 178 (only one shown) provideinitial movement of the frame blank 75 to the conveyor chains 190running over the sprockets 191 (see also FIGURE 30). The conveyor isprovided with a plurality of pusher elements 192 which move the frameblank after it has been removed from beneath the spring elemenst 171. Asillustrated in FIG- URE 30, the frame blank 75 is shown as it is aboutto be picked up by the conveyor 190. A second frame blank 75 is beingpushed downwardly by the pusher elements 192 carried by the conveyor190. As the frame blanks are moved by the conveyor 190, the end tab 62of each frame blank 75 passes over a folding cam 193 which causes theend tab 62 to be folded over on the score line 54. The end tab 62 isthen in position for further folding and tucking as will be apparent asthe description proceeds.

Cross direction folder section As aforesaid, the frame blanks 75 aremoved into the cross direction folder section by the conveyor 190. Indoing so the frame blank as seen in FIGURE 31 engages the foldingchannels 194 (see also FIGURE 3) and 195 which causes the frame blanksto be folded on the vertical scores 55 and 56. The frame blank is heldby friction in the cross direction folder section by the guide bars 196,197, and 198 which tend to hold the frame blank in the channels 194 and195.

The frame blanks are moved downwardly by the conveyor 190 and partiallythrough the cross direction folder section 85 as seen in FIGURE 3.Beyond the conveyor 190, choke feeding of frame blanks 75 causes them tocontinue their downward movement whereupon the panel 61 engages thefolding bar 199 to form the fold at the vertical score 57 as shown inFIGURE 32. Simultaneously, the folding channel 194 is curved outwardlyto open the frame blank as it moves into position over a bar 78 suchthat it can be placed around the bar.

The frame blank in the configuration shown in FIG- URE 32 is thereupondeposited around the bar 78 which is moved forward on the productconveyor 86 (see also FIGURE 4). The product conveyor 86 is providedwith pushers 200 which assure proper spacing of the bars 78 with respectto frame blanks and the machine elements when brought into assembledposition.

Final folding and end tab tucking section The partially assembled bar 78and frame 75 are carried forward by the pusher 200 on the conveyor 86and maintained in partially assembled relation by the guides 201 and 202(FIGURES 4 and 33). On arrival at the final folding and tucking stationthe mandrels 87 and 88 move in and grasp the frame blank pushinginwardly against the bar 78. The mandrels 87 and 88 may form a part ofan overwrap machine as described in the Hood patent, supra. The pusher200 is lowered by internal means (not shown) whereupon the assemblage isremoved from the conveyor 86 for the final tucking and foldingoperation.

A stationary folder bar 205 is mounted such that when the bar and frameassembly are rotated and translated by the mandrels 87 and 88 (FIGURE34), the folder bar 205 moves the panel 58 into position for finishingthe assembly. A stationary holder bar 206 is provided to engage thetubular supports 76 and 77 on the underside of the wall panel 58 toprevent it from being folded down too far by the folder bar 205. Thepulley 207 supports a belt 208 having pusher guides 209 projectingtherefrom. As the bar and frame asembly move into the final tuckingphase, the moving guide 209 supports the panel 58 to maintain it inalignment as the various folding elements are otherwise working on theframe.

A tucking bar 210 is provided to guide the end tab 62 into the spacebetween the wall panel 61 and its tubular supports 76 and 77. Therotating tucking cam 211 pushes the end tab 62 into place to completethe assembly of the supporting frame 79 around the bar 78.

Machine drive All of the heretofore described elements and mechanisms ofthe machine are driven in synchronous relationship by a fully integrateddrive that can operate continuously or intermittently as will be seenfrom a consideration of FIGURES 37, 38, and 39.

The main drive shaft 215 is driven by the chain 216 from a suitablesource (not shown). The endless chain 217 is driven from the main driveshaft 215 by means of the gear train 218 and 219. The chain 219 rotatesthe crank 107 (FIGURE 6) by means of the sprocket 220 connected to theshaft 221. The cam 116 is also driven by the shaft 221 (FIGURES 5. 37,and 38). Similarly, the drive for the crank (FIGURE 6) is from thesprocket 222 attached to shaft 223. The forwarding rolls 102 and 103 aredriven by a gear train 224, 225, and 226 from a shaft 27 driven by thegear 219.

A drive chain 228 driven from the main drive shaft 215 drives the belt119 by means of the sprocket 229. The chain 228 also drives a shaft 230by means of the sprocket 231. The forwarding rolls 126 and 127 (FIGURE2) are driven by the gear train 232, 233, and 234 from the shaft 230.Similarly, the shaft 230 drives the rolls 130, 131, and 132 by means ofthe chain 235 which drives the gear train 236, 237, 238, 239, and 240. Achain 241 is also driven from the shaft 230 and drives the shaft 242which in turn drives the folding roll 146 and the shaft 245 by means ofthe gears 243 and 244. The sheave 150 which supports one end of the belt151 is journaled on the shaft 245.

The shaft 216 is driven through the right angle gears 247 and 248. Theshaft 249 is driven from the right angle gears 250 and 251 to drive thebelt 151. The hold down belt 163 is driven from the shaft 249 by thegear train 252 and 253. The rotating bristled element 165 is driven fromthe shaft 249 by the gear train 254 and 255 acting through the belt 256(see also FIGURE 1). The shaft 257 is driven by the shaft 246 throughthe gear train 258, 259, 260, and 261.

The lateral chain conveyors 173 and 174 are driven by the shaft 257 asare the belts 167 and 168. The other end of the belts 167 and 168 aresupported by sheaves 262 and 263 which rotate freely on the drive shaft264 for the conveyor 190.

A separate drive is provided for the escapement linkage and the conveyor190 as best seen in FIGURES 37 and 39. The separate drive is normallyoperated synchronously with the other components of the machine. Whendesired, however, the separate drive can be independently operated toremove completed frame blanks 75 from the surge section 84 Withoutoperating the other components. The separate drive consists of a drivechain 265 suitably driven by a source (not shown) to drive the shaft266. The chain 267 is driven from the shaft 266 so that it rotates thedrive shaft 264 for the conveyor 190. In addition, the chain 267 rotatesthe sprocket 268 which drives the chain 269 for operation of theescapement linkage through the drive sprocket 270 which drives the shaft175.

Alternate bending mechanism An alternate mechanism for bending thepackaging blank 51 in the inner areas 71 and 73 is shown in FIG- URES 40and 41. The mechanism consists of a base 272 and a set of bending rolls.The bending rolls include upper rolls 273 and 274 which differ in widthas shown in FIGURE 40. As shown in FIGURE 41. the first set of bendingrolls also includes grooved bending rolls 275 and 276 which arecontoured to match the side and peripheral contour of the bending roll273.

The grooved bending rolls are supported by the carriages 277 and 278.The carriages 277 and 278 may be moved upwardly into engagement with thepackaging blank 51 moving beneath the bending roll 273 by means of thepneumatic cylinders 279 and 280. These cylinders may also be retractedif and when necessary to provide access to the bending rolls and/or toremove improperly formed blanks, etc.

Similarly, the second set of bending rolls includes the upper roll 274and the grooved rolls 281 and 282 supported on carriages 283 and 284 thelatter being actuated in similar fashion as the carriages 277 and 278.

In operation the bending roll set of FlGU RES 40 and 41 can be used inplace of the bending roll set shown in FIGURE 9 in the same relativeposition of the machine.

While particular embodiments of the invention have been illustrated anddescribed it will be obvious to those skilled in the art that variouschanges and modifications can be made without departing from the spiritand scope of the invention and it is intended to cover in the ap pendedclaims all such changes and modifications that are within the scope ofthis invention.

What is claimed as new is:

l. A machine for forming a frame blank for an article to be packaged,said apparatus comprising a hopper for receiving a plurality of fiatpackaging blanks in a stack, said blanks including a plurality ofadjoining wall panels and extending portions projecting laterally fromthe sides of said wall panels, means for moving a blank in said stack toa tubular support forming section, means at said section for folding,bending and forming the extending portions of said blank into a pair oftubular support elements extending longitudinaly along the side edges ofthe wall panels of said blank, and means for adhering the tubularsupport elements to the inner surface of the wall panels of said blankto complete the transformation of the flat packaging blank into a frameblank for an article to be packaged.

2. A machine for forming a frame blank as claimed in claim 1 whereinsaid folding, bending and forming means at said tubular support formingsection includes a plurality of sets of rolls for creasing and foldingthe extending portions of said packaging blanks along the preselectedlongitudinal score lines including the score lines separating the wallpanels of the blank from the extending portions thereof.

3. A machine for forming a frame blank as claimed in claim 2 including aplurality of sets of bending rolls for forming and contouring theextending portions of said packaging blanks intermediate the score linesdefining the inner area of the frame blank.

4. A machine for forming a frame blank as claimed in claim 3 whereinsaid creasing and folding rolls comprise a first set of folding rollsfor folding the score lines separating the outer and inner areas of saidpackaging blank, 21 second set of folding rolls for folding the scorelines separating the wall panels from the extending portions of saidblank, said bending rolls being located intermediate said first andsecond set of folding rolls.

5. A machine for forming a frame blank as claimed in claim 4 includingan extruder for applying a stripe of adhesive to the wall panels beneaththe formed tubular support elements, and means for thereafter foldingdown the tubular support elements against said adhesive stripes tocomplete the blank formation.

'6. A machine for forming a frame blank as claimed in claim 5 includinga compression section beyond said extruder for holding down said tubularsupport elements as the completed frame blanks move forward in themachine until the adhesive was solidified.

7. A machine for forming a frame blank as claimed in claim 1 whereinsaid hopper comprises a plurality of side walls for receiving a verticalstack of fiat packaging blanks, a plurality of curved blank supportsprojecting from the side walls of said magazine between the angularrelief cut-outs of said frame blanks, the lower portion of said blanksupports projecting forward such that successive blanks can be withdrawnand fed forward to said blank moving means.

8. A machine for forming a frame blank as claimed in claim 7 whereinsaid blank moving means comprises a plurality of vacuum cups and meansfor moving said vacuum cups into contact with the lowermost blank insaid hopper and thereafter moving said blank forward whereby it iswithdrawn from the bottom of said vertical stack.

9. A machine for forming a frame blank as claimed in claim 8 wherein themeans for moving the vacuum cups comprises a modified four-bar linkage.

10. A machine for forming a frame blank as claimed in claim 8 includinga pair of constantly driven forwarding rolls, said vacuum cupsdelivering successive blanks from the bottom of said stack in saidmagazine to said forwarding rolls for further movement through saidapparatus.

11. A machine for forming a frame blank as claimed in claim 10 whereinsaid blanks are delivered from said 13 forwarding rolls to an alignmentsection, means in said alignment section for bringing the side edges ofsuccessive fiat packaging blanks into edgewise alignment prior tofeeding said blanks into said tubular support forming section.

12. A machine for forming a frame blank as claimed in claim 11 includinga stationary guide at said alignment section, said guide being contactedby the side edges of successive fiat packaging blanks as they are movedthrough said alignment section such that the blanks are brought intoedgewise alignment.

13. A machine for forming a supporting frame for an article to bepackaged, said apparatus comprising a hopper for receiving a pluralityof fiat packaging blanks in a stack, said blanks including a pluralityof adjoining wall panels and extending portions projecting laterallyfrom the sides of said wall panels, means for moving a blank in saidstack to a tubular support forming section, means at said section forfolding, bending, and forming the extending portions of said blank intoa pair of tubular support elements extending longitudinally along theside edges of the wall panels of said blank, means for adhering'thetubular support elements to the inner surface of the wall panels of saidblank to complete the transformation of the flat packaging blank into aframe blank for an article to be packaged, a surge section, means forsuccessively forwarding each successive frame blank into said surgesection, means for successively removing frame blanks from said surgesection and feeding them into a cross direction folder section, means insaid cross direction folder for forming the frame blank into arectangular shape for placement around an article, and means for joiningthe free ends of the frame blank to complete a supporting frame for saidarticle.

14. A machine for forming a supporting frame as claimed in claim 13wherein said surge section includes means for moving successive frameblanks laterally, said surge section being of suflicient length to holdand accumulate a plurality of completed frame blanks at least equal innumber to the number of blanks being formed beginning from said hopper.

15. A machine for forming a supporting frame as claimed in claim 14including an escapement linkage at the end of said surge section, saidescapement linkage including a picker finger for picking successiveframe blanks and feeding them into the cross direction folder section.

16. A machine for forming a supporting frame as claimed in claim 15including means for preventing frame blanks being fed into said surgesection from bouncing oif the guide wall thereof.

17. A machine for forming a supportingYrame as claimed in claim 16wherein said bounce preventing means comprises a bristled wheel incontact with the frame blanks delivered to said surge section, saidwheel being driven such that its periphery moves in the direction ofmovement of the frame blanks delivered to said surge section.

18. A machine for forming a supporting frame as claimed in claim 16including means for carrying forward said article and means fordelivering the partially erected frame in place over an article movingon said conveyor.

19. A machine for forming a supporting frame as claimed in claim 18wherein said means for joining the free ends of the frame blank includesa means for tucking the end tab of said frame blank inside the oppositeend of said frame blank to complete the supporting frame.

20. A machine for forming a supporting frame as claimed in claim 13wherein said folding, bending, and forming means at said tubular supportforming section includes a plurality of sets of rolls for creasing andfolding the extending portions of said packaging blanks along thepreselected longitudinal score lines including the score linesseparating the wall panels of the blank from the extending portionsthereof.

21. A machine for forming a supporting frame as claimed in claim 20including a plurality of sets of bending rolls for forming andcontouring the extending portions of said packaging blanks intermediatethe score lines defining the inner area of the frame blank.

22. A machine for forming a supporting frame as claimed in claim 21wherein said creasing and folding rolls comprise a first set of foldingrolls for folding the score lines separating the outer and inner areasof said packaging blank, a second set of folding rolls for folding thescore lines separating the wall panels from the extending portions ofsaid blank, said bending rolls being located intermediate said first andsecond set of folding rolls.

23. A machine for forming a supporting frame as claimed in claim 22including an extruder for applying a stripe of adhesive to the wallpanels beneath the formed tubular support elements, and means forthereafter fold ing down the tubular support elements against saidadhesive stripe to complete the frame blank formation.

24. A machine for forming a supporting frame as claimed in claim 13wherein said hopper comprises a plurality of side Walls for receiving avertical stack of flat packaging blanks, a plurality of curved blanksupports projecting from the side walls of said magazine between theangular relief cut-outs of said frame blanks, the lower portion of saidblank supports projecting forward such that successive blanks can bewithdrawn and fed forward to said blank moving means.

25. An apparatus for forming a supporting frame as claimed in claim 24wherein said blank moving means comprises a plurality of vacuum cups andmeans for moving said vacuum cups into contact with the lowermost blankin said hopper and thereafter moving said blank forward whereby it iswithdrawn from the bottom of said vertical stack.

26. An apparatus for forming a supporting frame as claimed in claim 25including a pair of constantly driven forwarding rolls, said vacuum cupsdelivering successive blanks from the bottom of said stack in saidhopper to said forwarding rolls for further movement through saidapparatus.

References Cited UNITED STATES PATENTS 2,669,167 2/1954 Behl 93492,900,882 8/1959 Theobald 9384 BERNARD STICKNEY, Primary Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No.3,398,660 August 27, 1968 Howard N. Watrous It is certified that errorappears in the above identified patent and that said Letters Patent arehereby corrected as shown below:

Column 1, line 66, "later" should read lateral Column 3, line 59, "vew"should read View Column 5, line 55, "sequencse" should read sequenceline 65, "blangs" should read blanks Column 9, line 58, "illusrtated"should read illustrated line 65, "elemenst" should read elements Column12, line 43, after "the" insert frame Signed and sealed this 3rd day ofFebruary 1970.

(SEAL) Attest:

Edward M. Fletcher, Jr. WILLIAM E. SCHUYLER, JR. Attesting OfficerCommissioner of Patents

1. A MACHINE FOR FORMING A FRAME BLANK FOR AN ARTICLE TO BE PACKAGED,SAID APPARATUS COMPRISING A HOPPER FOR RECEIVING A PLURALITY OF FLATPACKAGING BLANKS IN A STACK, SAID BLANKS INCLUDING A PLURALITY OFADJOINING WALL PANELS AND EXTENDING PORTIONS PROJECTING LATERALLY FROMTHE SIDES OF SAID WALL PANELS, MEANS FOR MOVING A BLANK IN SAID STACK TOA TUBULAR SUPPORT FORMING SECTION, MEANS AT SAID SECTION FOR FOLDING,BENDING AND FORMING THE EXTENDING PORTIONS OF SAID BLANK INTO A PAIR OFTUBULAR SUPPORT ELEMENTS EXTENDING LONGITUDINALY ALONG THE SIDE EDGES OFTHE WALL PANELS OF SAID BLANK, AND MEANS FOR ADHERING THE TUBULARSUPPORT ELEMENTS TO THE INNER SURFACE OF THE WALL PANELS OF SAID BLANKTO COMPLETE THE TRANSFORMATION OF THE FLAT PACKAGING BLANK INTO A FRAMEBLANK FOR AN ARTICLE TO BE PACKAGED.